U.S. patent number 11,059,522 [Application Number 13/202,469] was granted by the patent office on 2021-07-13 for vehicle battery mounting structure.
This patent grant is currently assigned to NISSAN MOTOR CO., LTD.. The grantee listed for this patent is Tadayoshi Hashimura, Makoto Iwasa, Hidetoshi Kadota, Shinya Ogata, Satoshi Shigematsu. Invention is credited to Tadayoshi Hashimura, Makoto Iwasa, Hidetoshi Kadota, Shinya Ogata, Satoshi Shigematsu.
United States Patent |
11,059,522 |
Iwasa , et al. |
July 13, 2021 |
Vehicle battery mounting structure
Abstract
A vehicle (1) comprises a passenger compartment (2) in which a
front seat (32F), a rear seat (32R), and a floor (33) between the
front seat (32F) and the rear seat (38R) are provided. A first
group (S1) of batteries (3) is mounted under the front seat (32F),
a second group (S2) of the batteries (3) is mounted under the floor
(33), and a third group (S3) of the batteries (3) is mounted under
a rear seat (32R). By setting a height (h2) of the second group
(S2) of the batteries (3) to be lower than respective heights (h1,
h3) of the first and third groups (S1, S3) of the batteries (3), a
battery mounting capacity of the vehicle (1) can be increased
without affecting the comfort of the passenger compartment (2).
Inventors: |
Iwasa; Makoto (Chigasaki,
JP), Kadota; Hidetoshi (Yamato, JP),
Hashimura; Tadayoshi (Machida, JP), Ogata; Shinya
(Ebina, JP), Shigematsu; Satoshi (Yokohama,
JP) |
Applicant: |
Name |
City |
State |
Country |
Type |
Iwasa; Makoto
Kadota; Hidetoshi
Hashimura; Tadayoshi
Ogata; Shinya
Shigematsu; Satoshi |
Chigasaki
Yamato
Machida
Ebina
Yokohama |
N/A
N/A
N/A
N/A
N/A |
JP
JP
JP
JP
JP |
|
|
Assignee: |
NISSAN MOTOR CO., LTD.
(Yokohama, JP)
|
Family
ID: |
1000005672153 |
Appl.
No.: |
13/202,469 |
Filed: |
February 16, 2010 |
PCT
Filed: |
February 16, 2010 |
PCT No.: |
PCT/JP2010/052582 |
371(c)(1),(2),(4) Date: |
August 19, 2011 |
PCT
Pub. No.: |
WO2010/098270 |
PCT
Pub. Date: |
September 02, 2010 |
Prior Publication Data
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|
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Document
Identifier |
Publication Date |
|
US 20110300426 A1 |
Dec 8, 2011 |
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Foreign Application Priority Data
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Feb 24, 2009 [JP] |
|
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JP2009-041225 |
Jul 15, 2009 [JP] |
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JP2009-166942 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01M
50/249 (20210101); B60L 58/21 (20190201); H01M
50/298 (20210101); H01M 50/209 (20210101); B62D
25/20 (20130101); B60L 50/64 (20190201); H01M
10/0413 (20130101); B60L 58/26 (20190201); B60L
50/66 (20190201); B60L 50/16 (20190201); H01M
50/291 (20210101); H01M 50/244 (20210101); B60L
50/71 (20190201); B60L 58/40 (20190201); B60L
53/80 (20190201); B60L 50/51 (20190201); B62D
25/2036 (20130101); B60K 1/04 (20130101); B60L
50/72 (20190201); B60L 2240/26 (20130101); B60L
2210/40 (20130101); Y02T 10/70 (20130101); B60L
2210/30 (20130101); B60K 2001/0422 (20130101); Y02T
10/72 (20130101); Y02T 10/7072 (20130101); Y02T
90/12 (20130101); B60K 2001/0438 (20130101); H01M
2220/20 (20130101); Y02T 90/40 (20130101); Y02T
90/14 (20130101); B60K 2001/0433 (20130101) |
Current International
Class: |
B60L
50/51 (20190101); B60L 58/40 (20190101); B60L
50/60 (20190101); B60L 50/71 (20190101); B60L
50/16 (20190101); B60L 50/64 (20190101); B60L
50/72 (20190101); B60K 1/04 (20190101); B62D
25/20 (20060101); B60L 58/21 (20190101); H01M
50/298 (20210101); H01M 50/291 (20210101); B60L
58/26 (20190101); H01M 10/04 (20060101); B60L
53/80 (20190101); H01M 50/249 (20210101); H01M
50/209 (20210101); H01M 50/244 (20210101) |
Field of
Search: |
;180/68.5 |
References Cited
[Referenced By]
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WO |
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WO 2008-125946 |
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Oct 2008 |
|
WO |
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.
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|
Primary Examiner: Gilliam; Barbara L
Assistant Examiner: McDermott; Helen M
Attorney, Agent or Firm: Foley & Lardner LLP
Claims
The invention claimed is:
1. A vehicle mounting a plurality of batteries under a floor panel
of the vehicle, comprising: a first group of the batteries; a
second group of the batteries disposed to the rear of the first
group of the batteries with respect to a vehicle longitudinal
direction; and a third group of the batteries disposed to the rear
of the second group of the batteries with respect to the vehicle
longitudinal direction; wherein each of the first group of
batteries, the second group of batteries and the third group of
batteries has a topmost surface parallel to a road surface that the
vehicle is on and not in contact with other batteries or other
group of batteries, wherein, when measured from the road surface, a
height to the topmost surface of the second group of the batteries
is set to be lower than a height to the topmost surface of the
first group of the batteries and a height to the topmost surface of
the third group of the batteries, and the height to the topmost
surface of the third group of the batteries is set to be higher
than the height to the topmost surface of the first group of the
batteries, and wherein the vehicle comprises a passenger
compartment in which a front seat, a rear seat, and a floor located
between the front seat and the rear seat are provided, the first
group of the batteries is mounted under the front seat, the second
group of the batteries is mounted under the floor, and the third
group of the batteries is mounted under the rear seat.
2. The vehicle as defined in claim 1, wherein the second group of
the batteries comprises a plurality of the batteries having a
direction of stacking in a vertical direction and the third group
of the batteries comprises a plurality of the batteries having a
direction of stacking in a vehicle transverse direction.
3. The vehicle as defined in claim 2, wherein the first group of
the batteries comprises a plurality of the batteries having a
direction of stacking in a vertical direction.
4. The vehicle as defined in claim 1, further comprising a battery
mounting frame in which the first group of the batteries, the
second group of the batteries, and the third group of the batteries
are fixed in advance as a battery assembly, and the first group of
the batteries, the second group of the batteries, and the third
group of the batteries are fixed in the vehicle via the battery
mounting frame.
5. The vehicle as defined in claim 4, wherein the battery mounting
frame comprises a rectangular frame having a rectangular planar
shape and a reinforcing member fixed to an inside of the
rectangular frame.
6. The vehicle as defined in claim 5, wherein the rectangular frame
comprises a front edge member disposed at a front end thereof with
respect to the vehicle longitudinal direction, and the reinforcing
member comprises a girder fixed to the inside of the rectangular
frame in a vehicle transverse direction and a beam connecting a
girder and the front edge member, the girder and the beam forming a
T-shape in a plan view.
7. The vehicle as defined in claim 5, wherein the vehicle comprises
a fixed member for fixing the battery mounting frame.
8. The vehicle as defined in claim 6, wherein the first group of
the batteries and the second group of the batteries are fixed to
the rectangular frame in front of the girder with respect to the
vehicle longitudinal direction and the third group of the batteries
is fixed to the rectangular frame to the rear of the girder with
respect to the vehicle longitudinal direction.
9. The vehicle as defined in claim 4, further comprising a case
formed into a predetermined shape and fixed to the battery mounting
frame so as to accommodate the first group of the batteries, the
second group of the batteries, and the third group of the
batteries.
10. The vehicle as defined in claim 1, wherein the first group of
the batteries and the second group of the batteries comprise a
space in a center part with respect to a vehicle transverse
direction, and the batteries in the first group and the second
group comprise terminals projecting into the space.
11. The vehicle as defined in claim 10, wherein the batteries of
the third group comprise terminals projecting frontward with
respect to a vehicle longitudinal direction.
12. The vehicle as defined in claim 10, wherein: the vehicle
comprises a front compartment located in front of the passenger
compartment with respect to the vehicle longitudinal direction, an
electric equipment comprising an electric motor and a related
device as a motive force source for traveling is accommodated in
the front compartment, and the vehicle further comprises a harness
for connecting the terminals of the batteries of the first, second,
and third groups, and the electric equipment.
13. The vehicle as defined in claim 12, wherein the first group of
batteries includes a first stack of batteries and a second stack of
batteries positioned adjacent to the first stack of batteries in a
longitudinal direction of the first stack of batteries, the vehicle
including a space between the first stack of batteries and the
second stack of batteries, wherein the harness is disposed in the
space.
Description
FIELD OF THE INVENTION
This invention relates to a layout of batteries mounted on a
vehicle.
BACKGROUND OF THE INVENTION
Japanese Patent Serial No. 3199296, issued by The Japan Patent
Office in 2001, teaches placing a number of the batteries side by
side under a floor panel of a vehicle so as to mount as many
batteries as possible on the vehicle.
The batteries are arranged on a plain surface in a vehicle
transverse direction and a vehicle longitudinal direction closely
to form a battery group. A front seat and a rear seat are provided
in a passenger compartment of the vehicle and the battery group is
located under a floor panel of the passenger compartment including
regions for the front seat and the rear seat.
SUMMARY OF THE INVENTION
In the prior art battery mounting structure described above, the
batteries are arranged on a plain surface and have a uniform
height. In other words, if an increase in the battery mounting
capacity of the vehicle is required, the floor panel must be
raised, and as a result, the comfort of the passenger compartment
is impaired. Specifically, when the floor panel between the front
seat and the rear seat is raised, the foot position of passengers
sitting in the rear seat is raised and the passengers may feel
discomfort.
According to the prior art battery mounting structure, it is often
difficult to satisfy a requirement relating to the comfort of the
passenger compartment of a vehicle together with a requirement
relating to the battery mounting capacity of the vehicle.
It is therefore an object of this invention to provide a battery
mounting structure that can satisfy both of the above
requirements.
To achieve the above object, this invention provides a vehicle
battery mounting structure for mounting a plurality of batteries
under a floor panel of a vehicle, comprising a first group of the
batteries, a second group of the batteries disposed to the rear of
the first group of the batteries with respect to a vehicle
longitudinal direction, and a third group of the batteries disposed
to the rear of the second group of the batteries with respect to
the vehicle longitudinal direction. Herein, a height of the second
group of the batteries is set to be lower than a height of the
first group of the batteries and a height of the third group of the
batteries, and the height of the third group of the batteries is
set to be higher than the height of the first group of the
batteries.
This invention also provides a battery case fixed in a vehicle for
accommodating a stack of batteries, comprising a first battery
housing part, a second battery housing part disposed to the rear of
the first battery housing part with respect to a vehicle
longitudinal direction, and a third battery housing part disposed
to the rear of the second battery housing part with respect to the
vehicle longitudinal direction. Herein, a height of the second
battery housing part is set to be lower than a height of the first
battery housing part and a height of the third battery housing
part, and the height of the third group of the batteries is set to
be higher than the height of the first group of the batteries.
This invention also provides a battery mounting space formed in a
floor panel of a vehicle to face downward, comprising a first
recess, a second recess formed to the rear of the first recess with
respect to a vehicle longitudinal direction, and a third recess
formed to the rear of the second recess with respect to the vehicle
longitudinal direction. Herein, a height of a bottom of the second
recess is set to be lower than a height of a bottom of the first
recess and a height of a bottom of the third recess, and the height
of the third group of the batteries is set to be higher than the
height of the first group of the batteries.
This invention also provides a battery assembly fixed in a vehicle,
comprising a first group of batteries, a second group of the
batteries disposed to the rear of the first group of the batteries
with respect to a vehicle longitudinal direction, and a third group
of the batteries disposed to the rear of the second group of the
batteries with respect to the vehicle longitudinal direction.
Herein, a height of the second group of the batteries is set to be
lower than a height of the first group of the batteries and a
height of the third group of the batteries, and the height of the
third group of the batteries is set to be higher than the height of
the first group of the batteries.
The details as well as other features and advantages of this
invention are set forth in the remainder of the specification and
are shown in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view of essential parts of a
vehicle showing a vehicle battery mounting structure according to
this invention.
FIG. 2 is a horizontal sectional view of essential parts of the
vehicle showing the vehicle battery mounting structure.
FIG. 3 is a cross-sectional view of essential parts of the vehicle
taken along a line III-III of FIG. 2.
FIG. 4 is a plan view of a battery assembly according to this
invention.
FIG. 5 is a perspective view of the battery assembly.
FIG. 6 is a perspective view of a battery mounting frame according
to this invention.
FIG. 7 is an exploded perspective view of a vertical battery stack
according to this invention during a battery stacking process.
FIG. 8 is an exploded perspective view of a transverse battery
stack according to this invention during a battery stacking
process.
FIG. 9 is a perspective view of a case which accommodates the
battery assembly.
FIG. 10 is an electric circuit diagram of the battery assembly.
FIG. 11 shows an enlarged longitudinal sectional view of the case
and a battery mounting recess according to this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 of the drawings, a vehicle 1 comprises a
passenger compartment 2 and a front compartment 11 provided in
front of the passenger compartment 2. An arrow UP in the figure
points vertically upward and an arrow FR in the figure points
frontward with respect to running directions of the vehicle 1. The
vehicle 1 is a so-called electric vehicle which runs under a motive
force of an electric motor 12 housed in the front compartment 11.
The vehicle 1 may be a hybrid-drive vehicle which runs under a
motive force generated by an electric motor and a motive force
generated by an internal combustion engine or a fuel cell vehicle
which runs under a motive force generated by an electric motor that
is driven by electric power generated by fuel cells.
To drive the electric motor 12, a number of batteries 3 are
arranged in an under floor space of the passenger compartment 2 of
the vehicle 1.
Referring to FIGS. 2 and 3, a pair of parallel side members 4
extending in a vehicle longitudinal direction are provided under a
floor panel 16 forming a floor of the passenger compartment 2 of
the vehicle 1. An arrow WD in the figures points rightward in a
vehicle transverse direction when facing frontward with respect to
the running directions of the vehicle 1. Front ends of the pair of
side members 4 are fixed to a cross member 6 extending in the
vehicle transverse direction of the vehicle 1. A pair of rear side
members 9 are fixed to rear ends of the pair of side members 4.
Rear ends of the pair of rear side members 9 are fixed to a rear
cross member 10 extending in the vehicle transverse direction of
the vehicle 1.
Both ends of the cross member 6 and both ends of the rear cross
member 10 are fixed to a side sill 7 which delimits a lower end of
a door opening serving as a part of a vehicle body. The pair of
side members 4 are located on the inner side of the side sill 7 and
each of the side members 4 is fixed to the side sill 7 via three
outriggers 8. In FIGS. 2 and 3, a part designated by a reference
number 7 corresponds to an inner wall face of the side sill 7. The
members 4, 6, 9, and 10 are disposed in advance under the floor
panel 16 as a part of the vehicle body.
Referring again to FIG. 1, an electric motor 12 serving as a motive
force source for vehicle running, and a battery charger 13 and an
inverter 14 serving as related devices are housed in the front
compartment 11 of the vehicle 1. The battery charger 13 is a device
for charging the batteries 3. The inverter 14 is a device for
controlling charge/discharge of the batteries 3. In the following
description, the electric motor 12 and the related devices will be
referred to comprehensively as electric equipment.
Referring to FIGS. 4 and 5, the batteries 3 are stacked in advance
as a battery assembly 22 on the inner side of a battery mounting
frame 21 having a rectangular planar shape. The battery assembly 22
is then fitted into a space surrounded by the pair of side members
4, the cross member 6, the pair of rear side members 9, and the
rear cross member 10 from a lower side.
Referring to FIG. 6, the battery mounting frame 21 comprises a
rectangular frame 23 and a reinforcing member 24 which is arranged
in the rectangular frame 23.
The rectangular frame 23 comprises a front edge member 23f, a rear
edge member 23r, and a pair of side edge members 23s which connect
both ends of the front edge member 23f and both ends of the rear
edge member 23r. The front edge member 23f, the rear edge member
23r, and the pair of side edge members 23s form four sides of a
rectangle. It should be noted that the terms front-aft or front
end/rear end used in the description of the battery assembly 22
mean front-aft and front end/rear end in a state where the battery
assembly 22 is fixed to the vehicle body.
Each of the front edge members 23f, the rear edge members 23r, and
the pair of side edge members 23s is constituted by an upright wall
portion 28 and a flange portion 29 extending horizontally from a
lower end of the upright wall portion 28, thereby providing the
members 23f, 23r and 23s with an inverted T-shaped
cross-section.
The reinforcing member 24 comprises a girder 24w fixed in the
rectangular frame 23 in the vehicle transverse direction, and a
beam 24c connecting a middle part of the girder 24w and a middle
part of the front edge member 23f. The reinforcing member 24 is
integrated into the battery mounting frame 21 in advance by welding
the girder 24w and the beam 24c into a T-shape, and welding each
end of the resultant T-shape member to the rectangular frame
23.
According to the above structure, the inner space of the battery
mounting frame 21 is divided into a front rectangular region in
front of the girder 24w and a rear rectangular region 26R to the
rear of the same. The front rectangular region is further divided
into two front rectangular regions 26F, 26F by the beam 24c. A
total area of the two front rectangular regions 26F, 26F is
substantially the same as an area of the rear rectangular region
26R. The planar shape of these rectangular regions 26F, 26F, 26R is
designed such that a long side of the rectangle is substantially
double the size of a short side of the rectangle.
Referring to FIG. 7, each battery 3 is formed into a flat cuboid.
The batteries 3 are stacked in a direction of a shortest side of
the three sides of the cuboid. In the following description, the
other two sides are referred to as a long side and a short side
depending on a length of the sides.
In the two front rectangular regions 26F, 26F, the batteries 3 are
stacked in the vertical direction in a state where the long side of
the batteries 3 is oriented in the vehicle transverse direction and
the short side of the batteries 3 is oriented in the vehicle
longitudinal direction. In each of the front rectangular regions
26F, four stacks of the batteries 3 are arranged in the vehicle
longitudinal direction. The numbers of stacked batteries 3 are not
constant. In the frontmost two stacks in the region 26F, four
batteries 3 are stacked in each stack while in the rearmost two
stacks in the region 26F, two batteries 3 are stacked in each
stack. Thus twelve batteries are stacked in each of the rectangular
regions 26F, 26F.
In each stack in the front rectangular regions 26F, 26F, the
batteries 3 are stacked via spacers 37b and strip-form plates 37a.
The spacer 37b is a member comprising a columnar member and a large
diameter part formed in the middle of the columnar member via a
step on either side. Through-holes are formed through four corners
of the batteries 3 in advance so as to accommodate the columnar
part of the spacer 37b. Through-holes are also formed in the
strip-form plates 37a.
When the batteries 3 are stacked, one of the columnar parts of a
spacer 37b is inserted into a through-hole of the battery 3 after
passing through a through-hole of a strip-form plate 37a, and the
other columnar part of the spacer 37b is inserted into a
through-hole of an adjacent battery 3 after passing through a
through-hole of a different strip-form plate 37a. In this way, the
large diameter part of the spacer 37b is gripped between the two
batteries 3 via the strip-form plates 37a such that a stacking
clearance of the batteries 3 is kept constant. The strip-form plate
37a and a spacer 37c comprising a columnar member and a large
diameter part formed at an end of the columnar part via a step is
attached to an uppermost battery 3 and a lowermost battery 3.
Although not shown in the figures, a through-hole is formed axially
in each of the spacers 37b and 37c in advance. After stacking a
predetermined number of the batteries 3, a pin is caused to
penetrate the through-holes of the spacers 37b and 37c and a nut is
screwed on each end of the pin. The batteries 3 are thus integrated
into a battery stack.
Referring to FIG. 4, a space G is provided between the stacks in
one of the front rectangular regions 26F, 26F and the stacks in the
other of the front rectangular regions 26_F, 26F. The space G is
located above the beam 24c and a region adjacent to the beam 24.
The batteries 3 are stacked in the front rectangular regions 26F,
26F such that a terminal 3a of each battery 3 projects into the
space G. The terminals 3a of the batteries 3, a harness 34 which
electrically connects the terminals 3a and the electric equipment
in the front compartment 11, and a switch box 35 and a junction box
36 interposed in the harness 34 are accommodated in the space
G.
Referring to FIG. 8, twenty-four batteries 3 are stacked in the
transverse direction of the vehicle in the rear rectangular region
26R in a state where the long side of the battery 3 is oriented in
the vehicle longitudinal direction. The batteries 3 are stacked
with constant clearances via the spacers 37b such that the
terminals 3a project frontward. An end plate 37e is stacked on
either end of the stack.
Although not shown in the figures, a through-hole is formed axially
in each of the spacers 37b in advance. After stacking a
predetermined number of the batteries 3, a pin is caused to
penetrate the through-holes of the spacers 37b and a nut is screwed
on each end of the pin. The batteries 3 are thus integrated into a
battery stack.
A supporting plate 37d extending in the vehicle transverse
direction is fixed to a front side face and a rear side face of the
stack by screws 37f. Only one stack thus constructed is provided in
the rear rectangular region 26R.
Referring to FIG. 5, according to the above layout of the batteries
3, a group S1 of the batteries 3 comprising two stacks of four
batteries 3 stacked in the vertical direction and a group S2 of the
batteries 3 comprising two stacks of two batteries 3 stacked in the
vertical direction are provided in each of the two front
rectangular regions 26F, 26F in the battery mounting frame 21. A
group S3 of the batteries 3 comprising twenty-four batteries 3
stacked in the vehicle transverse direction is provided in the rear
rectangular region 26R in the battery mounting frame 21. With
respect to the stacking direction, the groups S1 and S2 constitute
a first battery unit 38F being a set of vertically stacked
batteries 3 while the group S3 constitute a second battery unit 38R
being a set of transversely stacked batteries 3.
Referring to FIGS. 3 and 9, a case 22a is fixed to the battery
mounting frame 21 so as to accommodate the battery assembly 22.
The stacks of the batteries 3 are fixed to the case 22a by screws,
for example. It is also possible to use the flange portion 29
extending inward from the upright wall portion 28 to fix the
stacks. The case 22a is formed into a shape adapted to the battery
assembly 22 in advance so as to prevent the stacks from displacing
in the transverse, longitudinal, and vertical directions. It is
preferable to form an opening or openings in a bottom of the case
22a to increase a cooling capability of the batteries 3. The shape
and the number of the openings may be determined arbitrarily.
Referring to FIG. 8, it is preferable to accommodate a control unit
45 constituted, for example, by a microcomputer to control the
devices in the junction box 36 in the case 22a on one side of one
of the end plates 37e.
Herein, the battery mounting frame 21, the case 22a, the stacks of
the batteries 3, the harness 34, the switch box 35, the junction
box 36, and the control unit 45 constitute the battery assembly
22.
Referring to FIGS. 1-4, the battery mounting frame 21 is fixed to
the cross member 6, the pair of side members 4, the pair of rear
side members 9, and the rear cross member 10 using bolts
penetrating the flange portion 29 that extends outward from the
upright wall portion 28 and nuts screwed onto the bolts. In the
fixed state, the upright wall portion 28 of the front edge member
23f faces the cross member 6, the upright wall portion 28 of the
rear edge member 23r faces the rear cross member 10, and the
upright wall portion 28 of the pair of side edge members 23s faces
the side members 4 and a part of the pair of rear side members 9,
respectively. Herein, the pair of side members 4, the cross member
6, the pair of rear side members 9, and the rear cross member 10
constitute a fixed member for fixing the battery mounting frame 21
onto the vehicle body.
The battery mounting frame 21 fixed to the fixed member assists in
increasing the rigidity and strength of the vehicle body. The
rectangular frame 23 and the reinforcing member 24 function as a
transferring path for loads input during a vehicle collision.
A downward opening 30 shown in FIG. 3 is formed in the vehicle body
by the pair of side members 4, the cross member 6, the pair of rear
side members 9, and the rear cross member 10, which constitute the
fixed member. The space above the opening 30 is covered by the
floor panel 16, thereby forming a housing recess 31 to accommodate
the battery assembly 22.
Mounting the battery assembly 22 on the vehicle body is performed
by inserting the battery assembly 22 into the housing recess 31
from below the vehicle body and fixing the battery mounting frame
21 to the fixed member using the bolts and nuts. By integrating a
number of the batteries 3 into the battery assembly 22 in advance,
mounting the batteries 3 on the vehicle 1 can be accomplished
easily. The batteries 3 thus mounted on the vehicle 1 can also be
removed easily for replacement.
As shown in FIG. 1, the vehicle 1 comprises a front seat 32F and a
rear seat 32R in the passenger compartment 2. The shape and size of
the battery assembly 22, the shape and the size of the batteries 3,
and the location of the fixed member are predetermined such that
the group S1 of the batteries 3 is located substantially below the
front seat 32F, the group S2 of the batteries 3 is located below
the floor 33 between the front seat 32F and the rear seat 32R, and
the group S3 of the batteries 3 is located below the rear seat 32R
in a state where the battery assembly 22 is fitted into the housing
recess 31. Further, the shape of the floor panel 16 and the case
22a are predetermined on the basis of the shape of the battery
assembly 22.
Assuming that the height of the group S1 of the batteries 3 is h1,
the height of the group S2 of the batteries 3 is h2, and the height
of the group S3 of the batteries 3 is h3, the relation
h3>h1>h2 holds. The heights h1 and h2 are common to the right
rectangular region 26F and the left rectangular region 26F.
The group S1 of the batteries 3 is located under the front seat
32F, and the group S3 of the batteries 3 is located under the rear
seat 32R. By setting the height h1 of the group S1 of the batteries
3 and the height h3 of the group S3 of the batteries 3 to be
greater than the height h2 of the group S2 of the batteries 3, a
space under the seats 32F and 32R in the passenger compartment 2
can be utilized efficiently for mounting the batteries 3, and a
large number of the batteries 3 can be mounted on the vehicle 1
without affecting the comfort of the passenger compartment 2. Since
the height h3 of the group S3 of the batteries 3 is higher than the
height h1 of the group S1 of the batteries 3, the sitting level of
the rear seat 32R becomes higher than the sitting level of the
front seat 32F in the passenger compartment 2. This setting is
preferable in terms of providing a wide view for passengers in the
rear seat 32R.
The groups S1 of the batteries 3 on the right and left of the beam
24 are constituted by sixteen batteries in total. The groups S2 of
the batteries 3 on the right and left of the beam 24c are
constituted by eight batteries in total. The group S3 of the
batteries 3 is constituted by twenty-four batteries. That is to say
twenty-four batteries are mounted in front of the girder 24w and in
the rear of the girder 24w, respectively. As a result, the weight
of the group S3 of the batteries 3 is heavier than the total weight
of the groups S2 of the batteries 3 and heavier than the total
weight of the groups S1 of the batteries 3, and substantially equal
to the total weight of the groups S2 of the batteries 3 and the
groups S1 of the batteries 3.
According to the above arrangement of the batteries 3, the center
of gravity of the battery assembly 22 is located to the rear of the
center of a plan view of the battery assembly 22. Assuming that Cv
in FIG. 4 is the graphical center of the vehicle 1, the center of
gravity of the battery assembly 22 is located to the rear of the
graphical center Cv of the vehicle 1. Considering that the electric
equipment comprising the electric motor 12, the battery charger 13,
and the inverter 14 is accommodated in the front compartment 11 of
the vehicle 1, locating the center of gravity of the battery
assembly 22 to the rear of the graphical center Cv of the vehicle 1
is preferable in terms of the weight balance of the vehicle 1 in
the front-aft direction.
In the groups S1 and S2 of the batteries 3, the batteries 3 are
stacked such that the long side is oriented in the vehicle
transverse direction and the short side is oriented in the vehicle
longitudinal direction. In this case, the density of the batteries
3 or the clearance between the batteries 3 in the vehicle
transverse direction is determined according to the width W of the
lower part of the vehicle body shown in FIG. 2 and the length Wb of
the long side of the batteries 3 shown in FIG. 4. With respect to
the groups S1 and S2 of the batteries 3, a space G formed between a
row of the battery stacks in one of the rectangular regions 26F and
a row of the battery stacks in the other rectangular region 26F
contributes to this adjustment of the clearance. In the groups S1
and S2 of the batteries 3, the batteries 3 are stacked in the
vertical direction. The respective heights h1 and h2 of the groups
S1 and S2 of the batteries 3 can therefore be adjusted minutely by
an adjustment unit equal to the length of the shortest side of the
battery 3.
With respect to the group S3 of the batteries 3, the batteries 3
are stacked such that the shortest side is oriented in the vehicle
transverse direction. Accordingly, by adjusting the stacking number
of the batteries 3 and the clearance between the batteries 3
depending on the width W of the lower part of the vehicle body, the
length of the group S3 of the batteries 3 in the vehicle transverse
direction can be adjusted minutely and a large number of the
batteries 3 can be mounted using the space under the rear seat 32R
efficiently.
According to the type of the vehicle 1, a rear space in the
passenger compartment 2 may be limited due to a rear wheel house 25
shown in FIG. 2 or a rear suspension. Since the dimension in the
vehicle transverse direction of the group S3 of the batteries 3,
which is located in the rear space in the passenger compartment 2,
can be adjusted minutely as described above, a difference in the
size of the rear space in the passenger compartment 2 can be
absorbed easily.
As shown in FIG. 1, the groups S1 and S2 of the batteries 3
respectively have two battery stacks arranged in the vehicle
longitudinal direction. However, this number of battery stacks can
be altered depending on the dimension of the vehicle 1 in the
longitudinal direction. For example, the group S1 of the batteries
3 may be constituted by three battery stacks arranged in the
vehicle longitudinal direction while the group S2 of the batteries
3 is constituted by only one battery stack.
Thus, even when the layout of the seats of the vehicle 1 is
changed, an optimum layout of the batteries can be realized by
simply altering the number of the battery stacks in the groups
S1-S3 without modifying the dimensions of the battery mounting
frame 21. As a result, the battery mounting frame 21 can be applied
to various types of vehicles.
According to the battery mounting structure described above, the
rear edge member 23r and the girder 24w of the battery mounting
frame 21 are located relatively near to the rear suspension. These
members bring about an effect of increasing the rigidity of the
vehicle body against a direct load input into the vehicle body when
a rear side of the vehicle 1 undergoes a collision or an upward
impact load transmitted from the rear suspension to the vehicle
body. In the group S3 of the batteries 3, by stacking the batteries
3 in close contact with one another and increasing the strength of
stack supporting members such as the supporting plates 37d, it is
possible to cause the battery stack to contribute to an increase in
the rigidity and strength of the vehicle body.
Since the harness 34, the switch box 35, and the junction box 36
are accommodated in the space G and the groups S1 and S2 of the
batteries 3 are stacked such that the terminals 3a project into the
space G. The space G, which is not used for stacking the batteries
3, is utilized effectively in the layout of these members. Putting
the first battery unit 38F constituted by the vertically stacked
batteries in front of the second battery unit 38R constituted by
the transversely stacked batteries is also preferable in terms of
obtaining the space for the layout of these members.
In the group S3 of the batteries 3, the batteries 3 are stacked
such that the terminals 3a project frontward, or in other words
into the upper space of the girder 24w. This layout of the
batteries 3 is preferable in terms of protecting the terminals 3 in
case of collision of the vehicle 1. Further, according to this
layout of the batteries 3, connecting the harness 34 to the
terminals 3a can be performed easily by using the upper space of
the girder 24w. Still further, the durability of the harness 34 can
be increased using the girder 24w to support the harness 34.
Referring to FIG. 10, an electric circuit of the battery assembly
22 will be described.
The electric circuit of the battery assembly 22 connects the
batteries 3 in the group S3 and the batteries 3 in the groups S1
and S2 on the right and left rectangular regions 26F in series
using the harness 34. The switch box 35 is interposed in the
harness 34 between the batteries 3 in the group S3 and the
batteries 3 in the groups S1 and S2. The junction box 36 is
interposed between the terminals connected to both ends of the
batteries 3.
The switch box 35 comprises a manually-operated relay 35a and a
fuse 35b connected in series. The manually-operated relay 35a
connects and disconnects the group S3 of the batteries 3 and the
groups S1 and S2 of the batteries 3. In this embodiment, the
electric circuit of the battery assembly 22 is divided into one
circuit for the first battery unit 38F constituted by the groups S1
and S2 of the batteries 3 in the right and left rectangular regions
26F and another circuit for the secondary battery unit 38R
constituted by the group S3 of the batteries 3. The terminal
voltage of the first battery unit 38F and the terminal voltage of
the second battery unit 38R are set to be equal in compliance with
SAEJ2344. The number of batteries stacked in each of the first
battery unit 38F and the second battery unit 38R is
twenty-four.
The junction box 36 comprises a main conductor 36a which
electrically connects a positive electrode of the first battery
unit 38F and the inverter 14, and a sub-conductor 36b which
electrically connects and disconnects a negative electrode of the
second battery unit 38R and the inverter 14.
Further, in the junction box 36, a pre-charge circuit 36c
comprising a resistor 36d and a pre-charge conductor 36e connected
in series is provided in parallel with the main conductor 36a.
Opening and closing operations of the main conductor 36a, the
sub-conductor 36b, and the pre-charge conductor 36e are performed
in response to opening/closing signals output from the aforesaid
control unit 45. The junction box 36 may further comprise a voltage
detecting device for detecting an output voltage of the battery
units 38F, 38R and a current detecting device for detecting a power
current output by the battery units 38F, 38R.
The switch box 35 is located farther from the inverter 14 than the
junction box 36, or in other words in the rearmost part in the
space G.
The switch box 35 is interposed between the first battery unit 38F
and the second battery unit 38R as described above. In a physical
sense also, the switch box 35 is preferably located near the
midpoint between the first battery unit 38F and the second battery
unit 38R so as to shorten the required length of the harness 34. In
FIG. 10, the junction box 36 is disposed between the battery units
38F, 38R and the electric equipment. In a physical sense also, the
junction box 36 is preferably disposed in front of the switch box
35 so as to shorten the required length of the harness 34.
In contrast, in a vehicle in which the electric equipment is
disposed in the rear of the battery assembly 22, the junction box
36 is preferably disposed in the rear of the switch box 35.
Referring again to FIG. 3, an opening 22b is formed in the case 22a
and a floor panel 16 covering the manually-operated relay 35a from
above so as to operate the manually-operated relay 35a in the
switch box 35 from within the passenger compartment 2. Further, a
lid 39 is provided to cover the opening 22b. The lid 39 is designed
to open and close such that the manually-operated relay 35a is
exposed to the passenger compartment 2 and hidden therefrom. The
switch box 35 is located between the right and left front seats
32F. By disposing the switch box 35 in this way, opening and
closing the lid 39 and operating the manually-operated relay 35a
can be conducted without displacing the front seat 32F. The switch
box 35 may however be disposed in a different location.
Finally, the case 22a and the battery housing recess 31 will be
described in detail.
Referring to FIG. 9, the case 22a comprises a first battery housing
part P1 for accommodating the first group S1 of the batteries 3, a
second housing part P2 for accommodating the second group S2 of the
batteries 3, and a third housing part P3 for accommodating the
third group S3 of the batteries 3. With respect to the vehicle
longitudinal direction, the second housing part P2 is located to
the rear of the first battery housing part P1 while the third
housing part P3 is located to the rear of the second housing part
P2.
Referring to FIG. 11, assuming that a height of the first battery
housing part P1 is h11, a height of the second housing part P2 is
h12, and a height of the third housing part P3 is h13, the relation
h13>h11>h12 holds.
The battery housing recess 31 is formed by the floor panel 16 and
the battery mounting frame 21 and has a sufficient capacity to
accommodate the groups S1-S3 of the batteries 3. The battery
housing recess 31 comprises a first recess Q1 formed under the
front seat 32F for accommodating the first group S1 of the
batteries 3, a second recess Q2 formed under the floor 33 for
accommodating the second group S2 of the batteries 3, and a third
recess Q3 formed under the rear seat 32R for accommodating the
third group S3 of the batteries 3.
Assuming that a height of a bottom of the first recess Q1 is h21, a
height of a bottom of the second housing part Q2 is h22, and a
height of a bottom of the third recess Q3 is h23, the relation
h23>h21>h22 holds.
The contents of Tokugan 2009-41225, with a filing date of Feb. 24,
2009 in Japan, and the contents of Tokugan 2009-166942, with a
filing date of Jul. 15, 2009 in Japan, are hereby incorporated by
reference.
Although the invention has been described above with reference to
certain embodiments, the invention is not limited to the
embodiments described above. Modifications and variations of the
embodiments described above will occur to those skilled in the
art.
For example, the shape of the batteries 3 is not necessarily a flat
cuboid. It is not vital that all of the batteries 3 have an
identical shape and identical dimensions.
Although in this embodiment, the two groups S1 and S2 of the
batteries 3 are provided as the first battery unit 38F, the first
vertical unit 38F may be constituted by one group of the batteries
3. Also in this embodiment, the space G is formed above the beam
24c so that the groups S1 and S2 of the batteries 3 are located on
the right and left of the space G. However, it is possible to
eliminate the space G and arrange the battery stacks of the first
battery unit 38F without a clearance in the vehicle transverse
direction depending on the width W of the lower part of the vehicle
body and the dimensions of the batteries 3.
The battery mounting frame 21 need not be made in a rectangular
shape, and may be made in a different shape depending on the type
of the vehicle 1. Instead of connecting the girder 24w and the beam
24c in a T-shape, they may be connected in a cruciform shape.
Further, the battery mounting frame 21 is not an essential
component of this invention. When the batteries 3 are mounted on a
vehicle without using the battery mounting frame 21, a preferable
weight balance in a front-aft direction of the vehicle is realized
by providing a first battery unit 38F comprising the vertically
stacked batteries 3 and a second battery unit 38R comprising the
transversely stacked batteries 3.
The electric circuit of the battery assembly 22 shown in FIG. 10 is
also not an essential component of this invention. This invention
can be applied to any vehicle on which a plurality of the batteries
3 are mounted irrespective of the electric circuit of the batteries
3.
INDUSTRIAL FIELD OF APPLICATION
As described above, the vehicle battery mounting structure
according to this invention is preferably applied to an electric
vehicle, but not limited thereto.
The embodiments of this invention in which an exclusive property or
privilege is claimed are defined as follows:
* * * * *